I might be able to talk Ruger into replacing the frame. The constriction in the bore has been my main concern but I've been looking at the hammer pin hole in the frame. It's not round. You can actually see the pin move around as you pull the hammer back.
Hammer down means the pin is at the top of it's hole.
Hammer under tension moves the pin lower in the hole and opens a gap above it.
I guess I got a Friday afternoon gun. Out of my 5 Rugers this is the only one with these problems. The others may not be on par with custom built guns but they are nowhere near this sloppy.